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<p>Thermal insulation tiles (TITs) are key components of thermal protection systems in hypersonic vehicles, providing essential shielding against extreme aerodynamic heating during flight. The reliability of these systems depends not only on the porous ceramic substrate, but also on the overlying coating and the coating–substrate interface. In this study, an integrated experimental and numerical approach was employed to investigate the uniaxial tensile behavior of both bare and coated TITs. A transversely isotropic damage constitutive model incorporating Hashin failure criterion was adopted to represent the macroscopic orthotropic behavior of the TITs. Finite-element (FE) analysis incorporating a cohesive zone model (CZM) was utilized to simulate the evolution of interfacial damage. The results demonstrated that the coating increased the tensile strength of the TITs from 0.74 MPa to 1.52 MPa, corresponding to an improvement of approximately 105%. FE–CZM simulations further revealed a coating–interface–substrate load-transfer failure sequence and identified the gage–transition edge region as the fracture-critical location. Quantitatively, the predicted tensile strengths agreed well with experimental data, with relative errors below 2% for bare TITs and 7% for coated TITs. These findings provide valuable insights for designing and optimizing TITs to enhance the safety of hypersonic vehicles.</p>

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Tensile Failure Characteristics of Bare and Coated Thermal Insulation Tiles: An Experimental and Modeling Study

  • 期刊论文

  • 发表日期：

    2026年3月9日

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  • Yiyang Hong,
  • Junchen Pan,
  • Zhenqiang Wu,
  • Xuejun Chen

摘要

Thermal insulation tiles (TITs) are key components of thermal protection systems in hypersonic vehicles, providing essential shielding against extreme aerodynamic heating during flight. The reliability of these systems depends not only on the porous ceramic substrate, but also on the overlying coating and the coating–substrate interface. In this study, an integrated experimental and numerical approach was employed to investigate the uniaxial tensile behavior of both bare and coated TITs. A transversely isotropic damage constitutive model incorporating Hashin failure criterion was adopted to represent the macroscopic orthotropic behavior of the TITs. Finite-element (FE) analysis incorporating a cohesive zone model (CZM) was utilized to simulate the evolution of interfacial damage. The results demonstrated that the coating increased the tensile strength of the TITs from 0.74 MPa to 1.52 MPa, corresponding to an improvement of approximately 105%. FE–CZM simulations further revealed a coating–interface–substrate load-transfer failure sequence and identified the gage–transition edge region as the fracture-critical location. Quantitatively, the predicted tensile strengths agreed well with experimental data, with relative errors below 2% for bare TITs and 7% for coated TITs. These findings provide valuable insights for designing and optimizing TITs to enhance the safety of hypersonic vehicles.